Method for processing materials

ABSTRACT

Systems and methods for thermal preservation (sterilization) of heterogeneous and multiphase foods and biomaterials in order to achieve their shelf stability at ambient level temperatures. Flowing heterogeneous, multiphase foods and biomaterials are exposed to single or multiple stages of electromagnetic energy under continuous flow conditions within conduits passing through the electromagnetic energy exposure chambers.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Continuation of U.S. patent application Ser. No.12/565,580, as filed on Sep. 23, 2009 now Pat. No. 8,337,920 whichclaims the benefit of priority under 35 U.S.C. §119(e) to the filingdate of U.S. Provisional Application No. 61/099,434, as filed on Sep.23, 2008 (“the '434 provisional application”), both of which areincorporated herein by reference in their entireties.

This application also is a Continuation of co-pending U.S. patentapplication Ser. No. 13/120,615, as filed on Mar. 23, 2011, which is anapplication filed under 35 U.S.C. §371 for PCT Application No.PCT/US2009/057603, which was filed on Sep. 20, 2009 and claims priorityto the '434 provisional application, each of which are incorporatedherein by reference in their entireties.

BACKGROUND

There is need for thermal preservation (sterilization) of heterogeneousand multiphase foods and biomaterials in order to achieve long shelfstability at ambient level temperatures. Methods are needed toeffectively heat flowing heterogeneous and multiphase foods andbiomaterials.

SUMMARY

In one embodiment, a method includes providing an electromagneticsystem. The electromagnetic system may comprise a first applicatorcomprising a entry end to receive electromagnetic energy, a terminationend, a waveguide, a material entry port, and a material exit port; and asecond applicator comprising a beginning portion, an end portion, awaveguide, a material entry port, and a material exit port. A firsttermination member may be attached to the termination end of the firstapplicator so that no electromagnetic energy transfers from the firstapplicator to the second applicator. Also, a second termination membermay be attached to the end portion of the second applicator so thatelectromagnetic energy does not proceed past the second terminationmember. At least one electromagnetic generator may be configured toprovide electromagnetic energy to the first and second applicators. Themethod may further include continuously pumping heterogeneous materialsthrough the first and second applicators so that the heterogeneousmaterials traveling through and exiting the first applicator is thendelivered through the second applicator and so that the heterogeneousmaterials absorb electromagnetic energy from the first applicator andabsorb electromagnetic energy from the second applicator. The methodalso may include delivering electromagnetic energy from at least oneelectromagnetic generator to the first and second applicators while theheterogeneous materials are being pumped.

In another embodiment, a system includes a conduit configured to carryheterogeneous materials that is pumped therethrough; a first applicatorcomprising an end portion, a waveguide, a material entry port, and amaterial exit port; a second applicator comprising a beginning portion,a waveguide, a material entry port, and a material exit port; and anelectromagnetic generator connected to the first and second applicatorsso as to provide electromagnetic energy to both the first and secondapplicators. The beginning portion of the second applicator is attachedto the end portion of the first applicator so that electromagneticenergy exiting the first applicator end portion is received by thebeginning portion of the second applicator.

In another embodiment, a system includes a first applicator comprisingan end portion, a waveguide, a material entry port, and a material exitport; an electromagnetic generator connected to the first applicator soas to provide electromagnetic energy to the first applicator; and aconduit comprising an interior and configured to carry heterogeneousmaterials comprising liquid and solid materials. The conduit is attachedto the first applicator so that the heterogeneous materials pass throughthe material entry port and the material exit port. The conduit interiorcomprises a top portion, a bottom portion and a center portion. Theconduit is aligned along the longitudinal length of the first applicatorso that a higher concentration of the electromagnetic energy is appliedto the bottom portion relative to the center and top portions of theconduit's interior thereby causing materials in the bottom portion ofthe conduit's interior to heat faster than materials in the center andtop portions of the conduit's interior.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the advantages of the invention will be readilyunderstood, a more particular description of the invention brieflydescribed above will be rendered by reference to specific embodimentsthat are illustrated in the appended drawings. Understanding that thesedrawings depict only typical embodiments of the invention and are nottherefore to be considered to be limiting of its scope, embodiments ofthe invention will be described and explained with additionalspecificity and detail through the use of the accompanying drawings, inwhich:

FIG. 1 illustrates a block diagram of a method for processing ofheterogeneous materials according to one embodiment of the presentinvention.

FIG. 2 illustrates a system for processing of heterogeneous materialsaccording to one embodiment of the present invention.

FIG. 3 illustrates a system for processing of heterogeneous materialsaccording to another embodiment of the present invention.

FIG. 4 illustrates a system for processing of heterogeneous materialsaccording to another embodiment of the present invention.

FIG. 5A illustrates a solid particle flow distribution at one stageaccording to one embodiment of the present invention.

FIG. 5B illustrates a solid particle flow distribution at another stageaccording to some embodiments of the present invention.

FIG. 6 illustrates a solid particle flow distribution at various stagesaccording to some embodiments of the present invention.

FIG. 7A illustrates a solid particle flow distribution at various stagesaccording to some embodiments of the present invention.

FIG. 7B illustrates a solid particle flow distribution at various stagesafter FIG. 7A according to some embodiments of the present invention.

FIG. 7C illustrates a solid particle flow distribution at various stagesafter FIG. 7B according to some embodiments of the present invention.

FIG. 7D illustrates a solid particle flow distribution at various stagesafter FIG. 7C according to some embodiments of the present invention.

FIG. 8 illustrates a block diagram of a method for processing ofheterogeneous materials according to some embodiments of the presentinvention.

FIG. 9 illustrates a cutaway view of static mixer design that may beimplemented into the thermal processing system according to someembodiments of the present invention.

FIG. 10 illustrates a cutaway view of another static mixer design thatmay be implemented into the thermal processing system according to otherembodiments of the present invention.

FIG. 11 illustrates a system for processing of heterogeneous materialsaccording to another embodiment of the present invention.

FIG. 12 a system for processing of heterogeneous materials according toanother embodiment of the present invention.

FIG. 13 a system for processing of heterogeneous materials according toyet another embodiment of the present invention.

FIG. 14 a system for processing of heterogeneous materials usingtermination members according to an embodiment of the present invention

DETAILED DESCRIPTION OF THE INVENTION

Reference throughout this specification to “one embodiment,” “anembodiment,” or similar language means that a particular feature,structure, or characteristic described in connection with the embodimentis included in at least one embodiment of the present invention. Thus,appearances of the phrases “in one embodiment,” “in an embodiment,” andsimilar language throughout this specification may, but do notnecessarily, all refer to the same embodiment.

FIG. 1 illustrates a sequence of operations for thermal preservation ofheterogeneous and multiphase foods using single or multi-stage exposureto electromagnetic energy under continuous flow conditions. The processmay begin with ingredients and pre-treatments of the ingredients inmaking food materials and other biomaterials. The biomaterials may beheterogeneous materials, or materials which include materials of varyingdensities. As illustrated a tank is pre-heated. The materials are loadedto a microwave system in order to heat or treat the materials loadedtherein. Such heating may occur in several stages. These heating stagesare illustrated and elaborated below regarding FIGS. 2 through 6.

FIG. 2 is a schematic outline of one of the embodiments of a heatingstage of the process for thermal preservation of flowable heterogenousmaterials (foods or biomaterials) by exposure of the process material toelectromagnetic energy under continuous flow conditions. Processmaterials enter the first applicator through process material entry port1 with an average temperature of T1AVG, maximum temperature T1MAX, and aminimum temperature of T1MIN. Concurrently, electromagnetic energy isintroduced into Applicator 1 through electromagnetic energy entry port1. Process material flows through a substantially horizontal conduitmade of material or combination of materials transparent toelectromagnetic energy. The horizontal flow is relative to ground orearth.

Typical materials for fabrication of these conduits are ceramics(typically Alumina ceramic), glass (typically Borosilicate glass) and/ora variety of plastic polymers (Teflon, polypropylene, polysulfone,polyetheretherketone (PEEK), and polyetherimide (Ultem)

During the flow through the transparent conduit within the firstapplicator the first increment of temperature increase of the processmaterial is realized. By the time process material exits the firstapplicator its average temperature has increased to T2AVG, its minimumtemperature to T2MIN and its maximum temperature to T2MAX. Concurrently,part of the electromagnetic energy which has entered Applicator 1 isabsorbed by the process material and converted to heat. Energy fielddensity of electromagnetic energy exiting the first applicator (atelectromagnetic energy exit port 1) and entering the second applicatorhas been reduced by the amount of energy absorbed by the processmaterial. Following exit from Applicator 1, process material is conveyedthrough a segment of conduit placed outside of the of electromagneticfield exposure. This segment can be modified in conduit profile,diameter, geometry or equipped with static or active in-line mixingdevices to improve the rate and extent of temperature equalization.Optionally, this segment can also be insulated or heated conventionally(tube in tube heat exchanger). Following temperature equalizationoutside of electromagnetic energy exposure region, process materialenters the second applicator with and average temperature of T3AVG,maximum temperature of T3MAX and minimum temperature of T3MIN, whereinthe difference (T3MAX−T3MIN) is substantially lower than the difference(T2MAX−T2MIN). Concurrently, electromagnetic energy exiting fromapplicator 1 via electromagnetic energy exit port 1 is conveyed via aconnecting waveguide into applicator 2 via electromagnetic energy entryport 2. Energy density/intensity level entering applicator 2 is lowerthan energy level originally delivered from the generator intoApplicator 1 through energy entry port 1.

Process material is further heated during conveyance through the secondapplicator—following material entry through material entry port 2.Electromagnetic energy continues to be absorbed while the processmaterial is exposed to its field while traveling through the secondconduit constructed from a single or combination of multipleelectromagnetic-energy transparent materials.

Optionally, transparent conduit placed within the second applicator canhave a different material structure and composition, design,cross-sectional profile or diameter. Exiting from the second applicator,process material temperatures are characterized by T4AVG, T4MIN andT4MAX temperature values wherein temperature differences T4AVG−T3AVG,T4MAX−T3MAX and T4MIN−T3MIN are preferably lower than respectivetemperature differences T2AVG−T1AVG, T2MAX−T1MAX and T2MIN−T1MIN.

Electromagnetic energy exits the second applicator with further reducedenergy density level and is optionally conveyed into the next entry portof another applicator or terminated with a water load. The secondapplicator may be terminated by a termination member, which may be awater load, a conductive plate that may set up a standing wave in thesecond applicator, or some other termination means to not allowelectromagnetic energy that has not been absorbed by the heterogeneousmaterials to exit the second applicator.

In one embodiment (as illustrated in FIG. 14), a material processingsystem is shown. A generator 104 provides electromagnetic energy (e.g.,microwave energy) to a first applicator 102. Another generator 110 mayprovide electromagnetic energy (e.g., microwave energy) to a secondapplicator 108 in one embodiment. A pump 112 may pump the heterogeneousmaterials through conduit 106, which enters the first applicator 102 ata first end and exits the first applicator 102 at a second end (whilebeing exposed to the electromagnetic energy provided by generator 104).The heterogeneous materials then travel through conduit 106 to enter thesecond applicator 108 at a first end and exit the second applicator 108at a second end (while being exposed to the electromagnetic energyprovided by generator 110).

The first applicator 102 may be terminated with a first terminationmember 105, which may be a water load, a conductive plate that may setup a standing wave in the first applicator 102, or some othertermination means to not allow electromagnetic energy that has not beenabsorbed by the heterogeneous materials to exit the first applicator 102and enter a second applicator 108. In addition, the second applicator108 may also be terminated with a termination member (i.e., a secondtermination member 116), which may be a water load, a conductive platethat may set up a standing wave in the second applicator, or some othertermination means to not allow electromagnetic energy that has not beenabsorbed by the heterogeneous materials in the second applicator to exitthe second applicator. Thus, in one embodiment, both the first andsecond applicators 102, 108 may have termination members 105, 116. Forexample, the first applicator 102 may be terminated with a first waterload that absorbs the electromagnetic energy not absorbed by theheterogeneous materials that travels through the first applicator 102,and the second applicator 108 may be terminated with a second water loadthat absorbs the electromagnetic energy not absorbed by theheterogeneous materials that travels through the second applicator 108.In another example, the first applicator 102 may be terminated with aconductive plate covering the second end of the first applicator 102 tocreate a standing wave in the first applicator 102, and the secondapplicator 108 may be terminated with a conductive plate covering theend of the second applicator 108 to create a standing wave in the secondapplicator 108.

The termination members 105, 116 may be different from each other. Forexample, the first applicator 102 may be terminated with a water loadwhile the second applicator 108 may be terminated with a conductiveplate. Regardless, in the embodiments where the first and secondapplicators 102, 108 each have termination members 105, 116, and whileelectromagnetic energy is not allowed to travel from the firstapplicator 102 to the second applicator 108 in these embodiments, thesame heterogeneous materials that is pumped from the first applicator102 (via pump 112) is then still pumped through the second applicator108. In this regard, electromagnetic energy is supplied to both thefirst and second applicators 102, 108 either separately by separategenerators (as illustrated) or by a single generator with a waveguidesplit (not illustrated). The electromagnetic energy that enters thefirst applicator 102 through conduit 106 is at least partially absorbedby the heterogeneous materials, and, similarly, when the heterogeneousmaterials enter the second applicator 108, electromagnetic energysupplied to the second applicator 108 is then at least partiallyabsorbed. This allows the heterogeneous materials to make two passesthrough two independent electromagnetic energy chambers (e.g., 102 and108), according to an embodiment. Because the electromagnetic energy isindependent in such embodiment, this may reduce hot spots causes by theelectromagnetic energy sources combining in one of the applicators. Itshould be understood that the above-discussed embodiments are onlyexemplary methods of processing the heterogeneous materials and otherconfigurations and methods are also possible as discussed andillustrated herein.

It should be noted that the heterogeneous materials that exit the secondapplicator 108 then continues to other processing systems 114, such asconstant heating systems, cooling systems, backpressure systems,packaging systems, or any other system for processing or handling of theheterogeneous materials.

Temperature levels and temperature ranges in all segments within theprocess material exiting the final applicator stage are sufficientlyhigh to achieve a pre-determined level of thermal preservation(pasteurization requiring subsequent refrigeration or sterilizationresulting in long-term shelf stability at ambient temperatures ofstorage and distribution) in the least thermally treated segment of thematerial after being subjected to a sufficient hold treatment.

The hold treatment is typically implemented by flowing the processmaterial through a segment of non-heating cylindrical profile conduitsegment long enough to achieve the predetermined level of productpreservation. Optionally, additional treatments and devices can beimplemented between the process material exit from the final applicatorexit port and entry into the hold segment—such as static or activeagitating devices in order to accelerate the equalization oftemperatures in the process material stream.

FIG. 3 illustrates the 3-stage of heating for thermal preservationand/or sterilization of heterogeneous (particle containing) foods byheating under continuous flow exposure to electromagnetic energy.

FIG. 4 illustrates the concept of heating for thermal preservationand/or sterilization of heterogeneous (particle containing) foods byheating under continuous flow exposure to electromagnetic energy.

Process material (particle-containing food or biomaterial) is introducedinto the electromagnetic energy exposure chamber via material entry port1 and conveyed under continuous flow conditions through amicrowave-transparent conduit C, fabricated from a single or combinationof materials from a group of ceramics, glass and polymer materials withhigh temperature-resistant, high pressure-resistant characteristics.

During the passage through the microwave-transparent conduit C,heterogeneous/particulate material is exposed to electromagnetic energywhich is absorbed by product constituents to varying levels.Electromagnetic energy is introduced through port A, propagates througha metal-walled series of waveguides and single or multiple exposurechambers to terminate in a water load. The electromagnetic exposurechamber in FIG. 4 can be considered to represent a single or multiplechambers required to achieve the desired temperature levels throughoutthe heterogeneous process material components.

Electromagnetic energy absorption and subsequent conversion to heatresult in the increase of temperature of process material. Theelectromagnetic energy exposure chamber D, or a series of similarexposure chambers are designed to allow for sufficient time and level ofexposure of process material to enable the lowest heated element in thematerial to achieve the condition of commercial sterility (shelfstability under ambient storage conditions) in the processedheterogeneous (particle-containing) food or biomaterial. Exposure withinthe single or multiple chambers is used to achieve predeterminedtemperature levels in the process material, sufficient to impartcommercial sterility to process material. These temperatures can rangefrom approximately 70 C to approximately 105 C for high acid foods andbiomaterials (e.g. fruits and products such as pickled vegetables,tomato dices and acidified salsa), and from approximately 110 C toapproximately 145 C for low acid foods and biomaterials (chunky soups,stews, cheese sauces with particles etc). Upon exit from the finalelectromagnetic exposure chamber, process material will be passedthrough a tube segment sufficiently long to enable maintenance of theprocess material at or above the predetermined temperature level for apredetermined amount of time under continuous flow conditions. This tubesegment is referred to herein as a hold tube. Typically, the lower thetemperature at the exit of the hold tube, the longer the hold tube willneed to be, since the sterilization treatment to achieve commercialsterility is a thermal process implementing a predetermined temperaturelevel treatment for a predetermined minimum amount of time. Thiscombination of time and temperature treatment is required to thermallyinactivate microorganisms which could potentially endanger health ofconsumers and/or spoilage of the product under typical conditions ofstorage and distribution.

FIG. 5 is an illustration of microwave transparent tube withheterogeneous product, i.e. carrier fluid and individual particulatecomponents with different density ranges continuously flowing through asubstantially horizontal tube under the regime of uniform heating of thecarrier fluid.

Any heterogeneous biomaterial, and especially foods containing particles(e.g., fluid with chucks), will contain solid pieces with a range ofdensity values. This is true even when there is a single solid componentwithin the product (e.g. tomato dices in tomato juice or blueberries inblueberry juice) and more so with multiple solid components present(e.g. fruit salad in syrup or minestrone soup). At lower flow rates(laminar flow conditions) particles that are at least 0.5% denser thanthe carrier fluid will tend to flow along the bottom segment of the tube(D), particles that are nearly identical in density to the carrier fluidare called neutral or neutrally buoyant (N) and tend to flow atlocations throughout the tube cross section—bottom, top and center.Particles which have density at least 0.5% lower than the carrier fluidwill tend to flow along the top of the tube and are marked as buoyant(B). As flow rates increase, flow conditions become more turbulent andlocations of flow for greater range of particle densities become moredistributed—i.e. denser particles tend to be lifted off the bottom andcarried in the fluid stream and buoyant particles will also get mixedinto other locations along the flow lines. Horizontal upward flow regimetherefore tends to equalize residence time solid particles (single ormultiple types) spend within a specific tube segment. Under other flowregimes (vertical upward or vertical downward) it would be impossible tomaintain this equalization over a range of densities.

FIG. 5B is a depiction of a process while heating a product containingdense, neutral and buoyant particle phases where the carrier fluid isbeing heated under continuous flow condition. A typical instance of thistype of heating would be tube in tube heat exchangers or volumetricheating wherein the carrier fluid has properties that allow it to beheated preferentially (dielectric properties and thermo-physicalproperties such as low heat capacity and high heat diffusivity). As theproduct flows from entry port, through the tube and out of the exit port(from right to left in FIG. 5 A), temperature of carrier fluid increaseswhich is accompanied by a decrease in its density. Since the solidparticles carried within the fluid do not heat as rapidly, neither theirtemperature nor their density changes significantly for some time. Thegradual reduction of density of the carrier fluid caused by heatingwithout the concurrent reduction of density of particles can lead to thesituation shown in the left-hand side of FIG. 5B, i.e. all containedsolid components (initially dense, neutral and buoyant) can end upflowing along the bottom of the tube due to having higher densities thanthe carrier fluid in some segments of process during heating.

FIG. 6—Stage 1 through Stage 3. Stage 1 depicted by FIG. 6 is the earlystage of heating—with buoyant particles flowing along the top of thetube, neutral particles occupying random locations along the crosssection of the tube and dense particles flowing along the bottom. Stage2 of FIG. 6—is the second stage of heating where the temperature of thecarrier fluid has been raised enough and its density has been reducedenough to cause settling out (flow along the bottom) of the initiallyneutral particles while the density of initially buoyant particles stillremains below the density of the carrier fluid and therefore theycontinue to flow predominately along the top segment of the tube.

Finally Stage 3 depicted by FIG. 6 is a stage where the carrier fluidtemperature has been raised high enough for its density to fall belowthe density of the initially buoyant particles, causing this productcomponent (B) to also fall out of suspension and flow along the bottomof the tube. Within the population of initially dense (D), initiallyneutral (N) and initially buoyant (B) particles, the flow will becomestratified—dense particles (D) will flow slower (and have longerresidence times) than initially neutral particles (N) which will in turnflow slower than the initially buoyant particles (B), provided the rateof change of their density values with temperature is equal or similar.

When such stratified product flow is subjected to heating, andespecially volumetric heating using electromagnetic energy undercontinuous flow conditions, this can result in wide differences inresidence times within the heating segments of the process (i.e. energyexposure chamber), resulting in significantly different extents of timeand temperature exposure for different solid components. With thefastest moving component the risk is to have it under-processed due toinsufficient residence time spent within the energy exposure segments ofthe process—and have a potential health hazard to the consumer. With theslowest moving component the risk is to over-heat and thereforeover-process that component resulting in excessive quality reduction andloss caused by thermal over-treatment.

FIG. 7 depicts stages 1 through 8 of heating of heterogeneous andmultiphase materials during flow through a substantially horizontalmicrowave-transparent conduit under exposure to electromagnetic energy,with increased energy exposure and increased heating rates in the bottomsegments of the conduit.

Embodiments of the present invention provides a means to address theproblem of density-base settling out of solid particulate food orbiomaterial components in thermal processing of heterogeneous foods andbiomaterials using electromagnetic energy heating under continuous flowconditions by application of electromagnetic energy. The key element ofthe invention is maintaining the preferential heating of processmaterial along the bottom segment of the flow-through, microwavetransparent conduit. This can be achieved by ensuring theelectromagnetic energy field remains stronger in the bottom segment ofthe flow-through tube throughout its exposure to the field. Thisarrangement enables a self-regulating process of dynamic density changesfor carrier fluid and solid components carried within it throughout theheating stages. This process of density change is elaborated in detailin FIG. 7—Stage 1 through FIG. 7—Stage 9.

Stage 1 of FIG. 7 shows the initial stage of heating—dense particles (D)flowing along the bottom, neutral particles (N) throughout the tube andbuoyant particles (B) along the top of the tube. Process material entersthe energy exposure chamber and preferential heating of the bottomsegment of the flow is initiated, causing the reduction of carrier fluiddensity along the tube bottom.

Stage 2 of FIG. 7—Carrier fluid temperature has been raised sufficientlyand its density reduced sufficiently to fall below the density of theneutral particles (N), causing them to settle to the bottom segment ofthe tube during flow.

Stage 3 of FIG. 7—Due to exposure to higher temperatures of the carrierfluid and higher energy field, initially dense (D) particle componentsare heated and their density reduced until it falls below the density ofthe carrier fluid and preferably below density of othersolid/particulate components of the product.

Stage 4 of FIG. 7—Due to its reduction in density caused by heating,initially dense (D) particle population moves upward through the carrierfluid and other solid components to be lifted to the top, colder regionsof the tube, and pushes the initially neutral (N) and initially buoyant(B) particle populations toward the center and bottom of the tuberespectively. This causes mixing between the particles and carrier fluidand contributes to equalization of both residence time and thermalexposure of all product components.

Stage 5 of FIG. 7—Initially neutral particles (N) flowing along thebottom segment of the tube get preferentially heated, reducing theirdensity and causing their move back through the middle and to the top ofthe flow profile—as depicted by Stage 6 of FIG. 7.

Stage 6 of FIG. 7—Density of initially neutral particles, due todistribution of energy and temperature increase has been reducedsufficiently to cause their movement towards to top of the flow region.

Stage 7 of FIG. 7—Initially neutral particles (N) move to the top whilethe initially dense segment starts losing some of the heat to thecarrier fluid surrounding it in the top, colder, less heated region ofthe tube—resulting in the relative increase of their density compared tothe carrier fluid component. Meanwhile, initially buoyant particlepopulation segment flowing along the tube bottom is heated by carrierfluid and surrounding electromagnetic energy field and its density isdecreased.

Stage 8 of FIG. 7—Initially buoyant (B) solid component after heating atthe bottom resulting in reduced density starts moving upward carried bythe difference in density between it and the carrier fluid, while theinitially dense (D) population starts falling out of the suspensiontowards the bottom of the flow due to higher density compared to thecarrier fluid.

Finally the process starts over again with Stage 1 of FIG. 7 where newmaterials are introduced into the tube and density—based spatial flowdistribution is reconstituted—with the initial flow distribution ofbuoyant particles (B) flowing mostly along the top, neutral particles(N) flowing throughout the tube and dense particles (D) flowing alongthe bottom of the tube is reestablished. Both horizontal (caused bypumping) and vertical (top to bottom and bottom to top) flow duringthermal exposure serve to equalize residence times and thermal exposureof all components contained within the product. Stage 1 of FIG. 7 alsore-establishes conditions for the described process to be restarted andreiterated at a higher temperature level. In this manner, preferentialheating along the tube bottom serves to not only equalize the treatmentthroughout the product but causes movement of all particles which in aheterogeneous product serve as miniature mixing devices assisting withthis equalization.

The thermal food processing process utilizes electromagnetic energy asthe primary source of process material heating while maintainingcontinuous flow of process material from the initiation of the processuntil process termination requires innovative design components. Theefficiency of this innovative thermal processing system causes theprocess material being pumped through the system to heat so rapidly thatthe total length has been significantly shortened. This shortening ofthe system length causes a reduction in natural back pressuresinherently present within conventional thermal processes. The loss ofthis internal process pressure due to shortened length coupled with theprocess material being heated above 100 C (boiling at standardatmospheric pressure) creates a situation where process material may“flash” or boil within the system piping. The superheated temperaturesare required to achieve the process goals, thus higher pressures withinthe superheated zones are required to prevent flashing of the liquidphase to vapor. Innovative design considerations must be utilized toestablish a stable, controllable and predictable system.

FIG. 8 illustrates the general flow of the system with components andfunctions described as:

-   -   A. Material to be Processed. Material is pumpable or capable of        moving through the system components in a controllable,        consistent manner. Material to be processed may be homogeneous        or heterogeneous, liquid, semi-solid or solid and may contain or        be absent of discrete particles. Material may be in a completely        natural, raw or non-processed state or may be processed or        pre-treated to any degree.    -   B. Continuous Flow Pump or Motive Device. Material to be        processed receives applied forces to establish continuous flow        at a relatively constant rate throughout the entire system until        termination of system flow requirements. Flow may be        sufficiently consistent to maintain control within the        operational parameters of the system as defined by the        application. Flow may be established through the use of positive        displacement pumps or pressurized systems with metered flow        control. Multiple motive devices may be placed in series at        determined intervals between the beginning and termination of        flow to provide for staged or designed pressurization within the        material conveyance system. The positive pumping characteristics        or pressure-based force establishes an operational condition        where downstream resistance to flow, whether artificial or        natural to the system design, increases the process material        pressure within the hermetic piping system. This internal        pressure is highest at the discharge of the pump or        pressure-based device and decreases as material flows toward the        termination of the system.    -   C. Electromagnetic Energy Heating Zone. Material to be processed        enters the Electromagnetic Energy Heating Zone where energy is        applied and absorbed by the process material. Energy is        converted to heat within the material creating the potential for        superheated zones where temperature with insufficient pressure        will result in “flashing” or the sudden conversion of liquid        (i.e. water) to vapor (i.e. steam). These vapor “pockets” result        in a loss of system control and predictability including, 1)        increased volume of material thus reducing designed residence        time within system components, 2) deposition of residue onto        system surfaces, 3) physical changes or damage to process        material, 4) undesirable cooling of process material, 5) loss of        function of system components (i.e.—pumps or back pressure        devices). Process material shall be at a predetermined        temperature upon exiting the heating zone.    -   D. Thermal Hold Zone. The Thermal Hold Zone is a designed        component of the process system, typically tubular, with a        predetermined length and volume that yields a specific residence        time for every particle of the process material at a given flow        rate. The hold zone cannot be designed to contribute additional        heating to the process material thus the temperature at the end        of the hold zone shall be the same or lower than the temperature        at the beginning of the hold zone. Temperatures within the hold        zone may be of a superheated nature and thus, require sufficient        pressure to remain in a non-vapor state as referenced in (C)        above. The designed residence time and “end of hold” temperature        serve as the legal thermal process of the system.    -   E. Cooling Device. Once the process material exits the Thermal        Hold Zone, the desired thermal process has been delivered and it        is typically desirable to cool the process material quickly. The        process material enters the cooling device but is still in a        superheated state thus, continues to require sufficient pressure        to remain in a non-vapor state. Multiple design and device        components may be integrated within the cooling device to        satisfy the system pressure requirements. Process materials may        be formulated to change rheological properties such as        thickening upon cooling thus providing resistance to flow and        increasing up-stream system pressure. Flow restrictors may be        designed in the cooling zone or non-cooling conveyance piping to        provide friction drag for up-stream pressure creation. These        devices may strictly be designed for resistance to flow or may        be multifunctional such as creating turbulence within the        cooling device for increased cooling efficiency.    -   F. Back Pressure Device. Upon exiting the cooling device, the        process material is no longer superheated to the level of        requiring sufficient pressure to prevent “flashing;” however, a        minimal pressure differential above the pressures external to        the system is required in commercially aseptic processing. This        nominal positive pressure differential is necessary to ensure        that conditions for egress of internal process material exist        and not ingress of external contamination into the system.        Multiple types of Back Pressure Devices may be mounted after the        exit of the cooling device to ensure all superheated areas        within the cooling device are protected. These devices have a        common characteristic of possessing a restrictive component to        process material flow that is adjustable through spring tension,        air pressure, hydraulic pressure, positioning device or other        resistive force application. Once the process material passes        the back pressure device, the resulting pressure is controlled        by the filler system, receiving surge tanks or a system exit        valve, marking the end of the continuous process.    -   G. Filler and/or Surge Tanks The final components of the        continuous process system will be a filler(s), storage or surge        tank(s) or a combination of the two functions. The termination        of the continuous process system may be fillers only with any        material not filled exiting the system though a final device        that acts as the back pressure device for the lower (filling)        pressure zone. Surge tanks may be located before the filler        systems or after the fillers as the termination point at the end        of continuous flow. One single surge tank shall be maintained at        the lower (filling) pressure allowing product to freely flow        from the process system supply or to the filling systems.        However, multiple surge tank systems can be utilized as        controlling devices for both high and low pressure zones by        isolating one tank and pressurizing to the higher level and        acting as a receiver tank. At a predetermined point, another        tank may act as the receiver tank and the initial tank pressure        is lowered to filling pressure and dedicated to filling only.

FIG. 12 depicts one embodiment of the utilization of an existingapparatus, where a static mixer is placed within the describedcontinuous flow electromagnetic thermal processing system (FIG. 11B) toattain desired back pressure within the process. Examples of staticmixers are illustrated in FIGS. 9 and 10. An increase in frictionalpressure caused by the use of a static mixer within a flowing systemshould be minimized. The utilization of static mixers are often reducedor avoided completely due to the addition frictional drag to the system.However, the unique characteristic of the electromagnetic thermalprocess system where the length has been dramatically shortened due tomore efficient heating creates an absence of natural systempressurization as compared to conventional thermal systems. This loss ofpressurization when coupled with superheated zones of process materialallows vaporization of liquids to gasses, thus rendering the processuncontrollable. The addition of static mixers creates significant andquantifiable pressure increases upstream of their location. Thesedevices may provide secondary process improvements through the creationof forced turbulence within the fluid flow on the continuous system orthe devices may only benefit the process through added back pressure. Itshould be noted that “back pressure” refers to applying a force to thematerials in a direction that is opposite of the flow of the material.The insertion of one or more static mixers after the end of the ThermalHold (ref. FIG. 12) and within the cooling device or any point beforethe filler and/or surge tank portion of the process will provideadditional back pressure within the system to maintain control of thefluid phase material in the superheated zones. A conscious design mustbe applied to quantify the pressure increase considering flow rate,process material physical characteristics, temperature, device type andlength, process equipment dimensions and location.

The utilization within the cooling device provides secondary benefits ofinduced turbulence resulting in a reduced boundary layer at the coolingsurface, thus improving the efficiency of cooling. Use of the staticmixers allows for larger clearances within the cooling device, thuscreating conditions that are induce less shear and mechanical stressesto the process material.

FIG. 13 depicts the utilization of smaller diameter piping within thedescribed continuous flow electromagnetic thermal processing system(FIG. 11C) to attain desired back pressure within the process. Thesmaller piping creates more friction drag thus resulting in an increasedback pressure within the system. The device may be placed after thecooling zone or may be designed to be within the cooling zone.

FIG. 11 depicts the utilization of an existing apparatus, a BackPressure Valve, within the described continuous flow electromagneticthermal processing system to attain desired back pressure within theprocess. The Back Pressure Valve should be located after the coolingdevice due to its nature of design.

Embodiments of the present invention may be embodied in other specificforms without departing from its spirit or essential characteristics.The described embodiments are to be considered in all respects only asillustrative and not restrictive. The scope of the invention is,therefore, indicated by the appended claims rather than by the foregoingdescription. All changes which come within the meaning and range ofequivalency of the claims are to be embraced within their scope.

What is claimed is:
 1. A method comprising: providing an electromagneticsystem comprising: a first applicator comprising a entry end to receiveelectromagnetic energy, a termination end, a waveguide, a material entryport, and a material exit port; and a second applicator comprising abeginning portion, an end portion, a waveguide, a material entry port,and a material exit port, wherein a first termination member is attachedto the termination end of the first applicator so that noelectromagnetic energy transfers from the first applicator to the secondapplicator, and wherein a second termination member is attached to theend portion of the second applicator so that electromagnetic energy doesnot proceed past the second termination member; and at least oneelectromagnetic generator that is configured to provide electromagneticenergy to the first and second applicators; continuously pumpingheterogeneous materials through the first and second applicators so thatthe heterogeneous materials traveling through and exiting the firstapplicator is then delivered through the second applicator and so thatthe heterogeneous materials absorb electromagnetic energy from the firstapplicator and absorb electromagnetic energy from the second applicator;and delivering electromagnetic energy from at least one electromagneticgenerator to the first and second applicators while the heterogeneousmaterials are being pumped.
 2. The method of claim 1, wherein the firsttermination member comprises an absorption load which absorbs theelectromagnetic energy not absorbed into the heterogeneous materials. 3.The method of claim 2, wherein the absorption load comprises a waterload.
 4. The method of claim 1, wherein the first termination membercomprises a conductive member which reflects the electromagnetic energynot absorbed into the heterogeneous materials.
 5. The method of claim 1,wherein the pumping heterogeneous materials comprises pumping theheterogeneous materials in a conduit which enters the first applicatorat the first applicator material entry port and exits the firstapplicator at the first applicator material exit port; and pumping theheterogeneous materials so that the heterogeneous materials that exitsthe first applicator at the first applicator material exit port entersthe second applicator at the second applicator material entry port andexits the second applicator at the first applicator material exit port.6. The method of claim 5, wherein the first applicator material exitport is located proximate to the first termination member of the firstapplicator.
 7. The method of claim 1, wherein the pumping heterogeneousmaterials comprises pumping the heterogeneous materials in a conduitalong a plane that is substantially along the longitudinal axis of thefirst applicator.
 8. The method of claim 7, wherein the pumpingheterogeneous materials comprises pumping the heterogeneous materials atan incline so that the heterogeneous materials are pumped against theforce of gravity.
 9. The method of claim 1, wherein the delivering theelectromagnetic energy comprises delivering the electromagnetic energyfrom a first electromagnetic generator to the first applicator while theheterogeneous materials are being pumped into the first applicator andfrom a second electromagnetic generator to the second applicator whilethe heterogeneous materials are being pumped into the second applicator.10. The method of claim 1 wherein the at least one generator comprises agenerator that provides electromagnetic power to both the first andsecond applicators.
 11. The method of claim 1, wherein the width, heightand depth of particles of the solid materials of the heterogeneousmaterials is at least one millimeter.